Self-retaining fastener and driver

ABSTRACT

A provisional engagement feature for selectively connecting a fastener such as a screw to a driving tool, the fastener incorporating a head with a recess extending therein and a projection contained within the recess for engagement with a corresponding engagement feature of the driving tool.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation application of U.S. patentapplication Ser. No. 14/645,726 entitled “Self-Retaining Fastener andDriver,” filed Mar. 12, 2015, which in turn claims the benefit of U.S.Provisional Patent Application Ser. No. 61/951,601 entitled“Self-Retaining Screw and Driver,” filed Mar. 12, 2014, and U.S.Provisional Patent Application Ser. No. 61/988,932 entitled“Self-Retaining Screw and Driver,” filed May 6, 2014. The disclosures ofeach of these documents are incorporated by reference herein in theirentireties.

TECHNICAL FIELD

The present invention relates generally to fasteners and, in particular,relates to a self-retaining fastener and fastener driver for installingthe fastener into a structure or work piece for use in a variety ofindustries, including, but not limited to, construction, engineering,manufacturing and medical treatment applications.

BACKGROUND

Fasteners re used to secure a multitude of different components andmaterials together for a variety of applications including, but notlimited to, assembling and securing manufacturing components, connectingbuilding materials such as metal, polymer, plastic or wood, and the useof fasteners for attachment to biological materials such as bone and/orsoft tissue during medical treatment procedures. In many cases,fasteners can include a generally cylindrical body having an externalthread (i.e., a thread-based fastener or “screw”), in which a generallycylindrical screw body is formed separate from an associated driving orfixating tool (i.e., a “driver”), with the driver removed from the screwonce the securing operation is completed (and the screw is left behindin the construct or work piece). There is a constantly increasing numberand variety of applications for the use of screw-based fasteners, butone consistent need encountered in many applications is a desired forthe driver to temporarily “hold,” center and/or otherwise retain and/orsecure the fastener (i.e., to the driver) prior to and/or during thesecuring operation into the particular material and/or structure, yetwhich allows the driver to be quickly and easily removed from thefastener once the connection operation is completed. This is especiallytrue where the driver requires two hands to manipulate and/or operate,where it may be advantageous for an individual to use one hand for thedriver and the other to hold the work piece accepting the fastener, andwhere a dropped and/or lost screw can cause unintended damage and/orlong term consequences (i.e., during a medical procedure and/or duringaircraft engine repair).

In the biomedical field, an increasing number of applications are beingdeveloped which involve the use of mechanical fastener constructs thatare surgically implanted to allow the body to mend or be reconstructed(i.e., temporarily and/or permanently). Such applications can includefasteners used with spinal constructs and disk replacements, plates usedfor long bone repair from the femur to the metacarpals, and even softtissue repairs such as tendon and ligamentoplasty, as well as bladderand hernia repair. In many instances, a surgeon may only have a singlehand free to operate the driver (or the surgical field may not allow formore than a single hand and/or the driver tip to penetrate the patientand/or the surgical field). Moreover, a fastener that unintentionallydislodges or otherwise “drops” into a wound can cause significant damageto the patient as well as potentially become “lost” within the wound -often with long term consequences for the patient.

There are many orthopedic surgical and dental procedures in which afastener is implanted to hold bone in a certain position and/or toprovide an anchor for a dental or other prosthetic or implant. In smallbone surgery (e.g., below the elbow and ankle), the available fastenerproducts are typically scaled-down versions of larger fasteners used forlarger bones, and these versions are often not adequate for the finebones and delicate procedures required of the small bone surgeon. Inparticular, the small bones are often fine and have minimal surface areafor placement of an implant, and typically less mass for placement of ascrew-type fastener. In addition, there is usually minimal soft tissuein the regions to “cover” and/or cushion an implant. These factors tendto make small bone surgery particularly tedious and unforgiving.Consequently, it is desirable to have surgical tools for small bonesurgery that provide assistance in holding, centering and/or implantingthe delicate screw that are used in this areas of the body—especiallywhere the design allows fewer “hands” to be involved in the procedureand does not significantly increase the dimensions and/or “profile” ofthe screw head.

SUMMARY OF THE INVENTION

In accordance with various aspects of the present invention, a fastener,such as a screw-type fastener, includes a proximal end and a distal end,with a shaft or other body extending at least partially from theproximal end to the distal end. The shaft desirably includes anexternally threaded portion for securing the fastener to a structurewith a driving, fixating or placement tool. The fastener desirablyincludes a head incorporating a driving feature located at the proximalend, the head having an axial end surface and a recessed portionincluding an axially extending first inner surface within the recess.The recess desirably extends from the axial end surface towards a distalend of the fastener, with the first inner surface including at least oneprojection or other feature extending proximally from the first innersurface, the projection being sized and/or configured to engage with acorresponding engagement feature of the driving or placement tool. Invarious embodiments, the engagement between the projection and theengagement feature is a friction fit, while in other embodiments theengagement can comprise a detent-type mechanism or a positivelocking-type fit.

In accordance with another aspect of the present invention, a screw andscrewdriver combination includes a screw extending along an axis andhaving a proximal end and a distal end. A head located at the proximalend has an axial end surface and an axially extending first innersurface defining a recess. The recess extends from the axial end surfacetowards the distal end of the screw and terminates at a second innersurface. Optionally, a projection may extend from the second innersurface towards the axial end surface and terminate at a proximalextent. The projection has an engagement feature, such as a frictionfit, detent-type mechanism or a positive locking-type fit with a tool. Ashaft extends from the head and incorporates a thread for securing thescrew into a work piece with the tool. The screw further includes ashaft extending from the head and having a thread for securing the screwin a structure/work piece. A screwdriver extends along an axis and has aproximal end and a distal end. A handle is located at the proximal endof the screwdriver and a shaft extends distally from the handle. A pilotlocated at the distal end of the screwdriver can cooperate with thefirst inner surface of the screw.

In accordance with another aspect of the present invention a surgicalscrew has a proximal end and a distal end. The screw includes a headlocated at the proximal end and having an axial end surface and anaxially extending first inner surface that defines a recess. The recessextends from the axial end surface towards the distal end of the screwand terminates at a second inner surface. A projection extends from thesecond inner surface towards the axial end surface and terminates at aproximal extent. The projection has an engagement feature thatprovisionally engages the projection with a corresponding feature of atool. A shaft extends from the head and has a thread for securing thescrew in bone with the tool.

In accordance with another aspect of the present invention a surgicalscrew and screwdriver combination includes a surgical screw extendingalong an axis and having a proximal end and a distal end. A head locatedat the proximal end has an axial end surface and an axially extendingfirst inner surface defining a recess. The recess extends from the axialend surface towards the distal end of the screw and terminates at asecond inner surface. A projection extends from the second inner surfacetowards the axial end surface and terminates at a proximal extent. Thescrew further includes a shaft extending from the head and having athread for securing the screw in bone. A screwdriver extends along anaxis and has a proximal end and a distal end. A handle is located at theproximal end of the screwdriver and a shaft extends distally from thehandle. A pilot located at the distal end of the screwdriver cooperateswith the first inner surface of the screw. The pilot has an innersurface that forms an engagement feature with the projection of thescrew.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other objects, aspects, features, and advantages ofembodiments will become more apparent and may be better understood byreferring to the following detailed description of the preferredembodiments, taken in conjunction with the accompanying drawings,wherein:

FIG. 1 is a schematic illustration of a self-retaining fastener andfastener driver in accordance with an aspect of the present invention;

FIG. 2 is an isometric view of the fastener of FIG. 1;

FIG. 3 is a sectional view taken along line 3-3 of FIG. 2;

FIG. 4 is a top view of the fastener of FIG. 2;

FIG. 5 is a side view of the fastener driver of FIG. 1;

FIG. 6A is an enlarged view of a portion of the fastener driver of FIG.5;

FIG. 6B is a bottom view of the fastener driver of FIG. 5;

FIGS. 7A-7C are schematic views illustrating a method of installing thefastener of FIG. 2 in bone using the fastener driver of FIG. 5;

FIGS. 8A and 8B illustrate a fastener having an alternativeconfiguration;

FIGS. 9A and 9B illustrate a fastener having another alternativeconfiguration;

FIGS. 10A and 10B illustrate a fastener having another alternativeconfiguration;

FIGS. 11A and 11B illustrate a fastener having another alternativeconfiguration;

FIGS. 12A and 12B illustrate a fastener having another alternativeconfiguration;

FIGS. 13A through 13D illustrate various view of a fastener havinganother alternative configuration;

FIGS. 14A through 14E illustrate various views of a fastener havinganother alternative configuration;

FIGS. 15A through 15D illustrate various views of a fastener havinganother alternative configuration;

FIGS. 16A through 16D illustrate various views of a fastener havinganother alternative configuration;

FIGS. 17A through 17D illustrate various views of a fastener havinganother alternative configuration;

FIGS. 18A through 18D illustrate various views of a fastener havinganother alternative configuration;

FIGS. 19A through 19D illustrate various views of a fastener havinganother alternative configuration;

FIGS. 20A through 20D illustrate various views of a fastener havinganother alternative configuration;

FIGS. 21A through 21 C illustrate various views of another exemplaryembodiment of a driving tool for use with various fasteners of thepresent invention;

FIG. 22A depicts a cross-sectional view of one alternative embodiment ofa pilot of a driving tool taken along line 22A-22A of FIG. 21C;

FIG. 22B depicts a cross-sectional view of another alternativeembodiment of a pilot of a driving tool taken along line 22B-22B of FIG.21C;

FIG. 22C depicts a cross-section view of another alternative embodimentof a pilot of a driving tool taken along line 22C-22C of FIG. 21C; and

FIG. 22D depicts a cross-section view of another alternative embodimentof a pilot of a driving tool taken along line 22D-22D of FIG. 21C.

DETAILED DESCRIPTION

Various features of the present invention include the recognition of aneed for a more effective system of provisionally connecting a fastener,such as a screw-based or other type of fastener, to a driving orplacement tool, thereby allowing the fastener to be carried and/orpositioned solely by manipulation of the tool, and then attached orintroduced into a work piece by actuation of the tool, with the toolbeing quickly and easily detached from the fastener once the fastener isin a desired position. A variety of configurations, sizes and shapes ofsuch fasteners and associated tools can be utilized in diverseenvironments, which can range from construction and manufacturing to usein surgery and medical procedures. In various medical applications, thedisclosed fasteners and related tools and techniques can desirablyfacilitate the use of various fasteners by surgeons, which can beimportant to achieve the most accurate and best performance and/or fitof implant components.

It will be apparent that a fastener and associated fastening tool with aprovisional engagement system such as described herein can provide anumber of attendant advantages, including the ability to “preload” afastener onto a tool, which allows the tool to be freely manipulatedwith one or both hands and the fastener utilized without concern thatthe fastener will unintentionally separate from the tool. Similarly, theprovisional engagement systems described herein can allow a fastener tobe removed from a work piece, with the fastener desirably retained bythe removal tool (and then easily removed from the tool by a user),which can obviate dropped and/or lost used fasteners and facilitatesquick and easy fastener removal and disposal.

In various embodiments, the ability to provisionally engage a fastenerto a driving tool can significantly reduce the opportunity for damagingthe fastener due to insufficient contact between the fastener head andthe driving bit during the installation and/or removal procedure (i.e.,“stripping out” of the fastener head). Similarly, the various featuresdescribed herein can reduce and/or eliminate the tendency for a fastenerto “wobble” in the driving tool during initial placement of the fastener(i.e., various embodiments can “self-center” the fastener on the tool),which can prolong the life of the fastener and/or the driving tool, aswell as significantly reduce the opportunity for unwanted damage to thework piece.

The present invention relates generally to fasteners and, in particular,relates to a self-retaining screw and screwdriver for installing thescrew in a desired structure. The structure may comprise, for example, asubstrate including a metal, polymer, plastic, ceramic, wood, bone orother biological tissue. In addition, while various embodiments hereindescribe a cylindrical screw body with externally-extending threads, awide variety of other fastening arrangements known in the art could beutilized in combination with the various teachings provided herein,including, but not limited to, the use of twist-lock or expansion-typefasteners, machine-type fasteners, spring-loaded fasteners, rivets orvirtually any other type of removable fastener and associated placementand/or driving tools.

FIG. 1 illustrates a self-retaining screw 30 and associated screwdriver150 in accordance with an aspect of the present invention. Thescrewdriver 150 and screw 30 are desirably self-aligning and include oneor more features that provide a friction fit or other selectableretention relationship between the screw and screwdriver, such that thescrew remains provisionally connected to the screwdriver withoutrequiring the operator to manually hold the screw onto the screwdriver.

Referring to FIGS. 2-4, the screw 30 has a first or proximal end 34 anda second or distal end 36. The screw 30 extends along an axis 32 and maybe formed from any material, e.g., a metal, polymer or a biocompatiblematerial. The screw 30 includes a head 40 and a shaft 80 extending fromthe head along the axis 32. The shaft 80 has an elongated shape with acircular cross-section having a diameter Φ₁. Alternatively, the shaft 80may taper inwardly in a direction extending towards the distal end 36 ofthe screw 30 (not shown). A thread 82 extends radially outward from theshaft 80. In one example, the thread 82 constitutes a cancellous threadhaving a substantially constant outer diameter 12. It will beappreciated, however, that the thread 82 may have alternative threadconfigurations, e.g., square, buttress, sawtooth, etc., and/or have avariable outer diameter Φ₂ tailored for ease of manufacture, loadcarrying capacity, ease of use and/or securing the screw 30 to aparticular structure and/or environment. The thread 82 in the disclosedembodiment forms a spiraling, helical pattern around and along the shaft80 from a location adjacent the head 40 to the distal end 36 of thescrew 30.

The distal end 36 of the screw 30 terminates at a cutting tip 90 formedby a plurality of sharp, angled flutes 92 collectively defining a recess94. Alternatively, the distal end 36 of the screw 30 may terminate at ablunt tip (not shown). A recess 88 or “cutting tooth” (or other similarfeatures) can be formed in the thread 82 and can extend approximatelyparallel to the axis 32 from the tip 90 towards the first end 34 of thescrew 30. Alternatively, the thread 82 and the tip 90 may incorporateself-tapping characteristics and/or lead type screw designs. Such leadtype screw designs, include single lead, dual lead, triple lead, and/orquad lead to affect their static or quasi-static performance, such asefficiency, driving torque requirements, increased number of engagementpoints and load capacity. The self-tapping characteristics may includethread-forming or thread cutting features, if desired.

Referring to FIG. 3, the head 40 of the screw 30 includes a generallyaxial end surface 42. A rounded surface 44 connects the axial endsurface 42 to the shaft 40. The axial end surface 42 may be rounded,planar (not shown) or any other desired shape, with the screw headformed in almost any configuration, including square and/or hexagonal.The rounded surface 44 may be configured to mimic the contour of thestructure to which the screw 30 is secured, and if desired mayincorporate roughened and/or cutting surfaces to prepare and/or engagewith underlying surfaces of the substrate. For medical applications, forexample, the rounded surface may be configured to mimic the contour ofan underlying bony surface to which the screw is secured, or the roundedsurface may prepare the underlying bony surface and/or include surfacefeatures that can osseo-integrate with the bone surface, if desired. Arecess 50 extends inward from the axial end surface 42 towards the shaft80. The recess 50 can have a depth D₁ measured from the axial endsurface 42 to a bottom or inner end surface 54 within the screw 30 or aplurality of such surfaces of varying depths is similarly contemplatedby the present disclosure. The inner end surface 54 may be locatedwithin the head 40, as shown, or may be located within the shaft 80 (notshown), or may extend within both the head and shaft (not shown), ifdesired.

Referring to FIG. 4, the recess 50 in the disclosed embodiment isfurther defined and bounded by a generally longitudinally-extendinginner surface 52 of the head 40. In the disclosed embodiment, the innersurface 52 is formed in a generally hexalobular shape that is positionedat a location generally symmetrical about the axis 32, but suchpositioning may be asymmetrical (not shown), if desired. Thelongitudinally-extending inner surface 52 of the disclosed embodiment isgenerally perpendicular to the inner end surface 54, but may taperinwards and/or outwards to varying degrees, if desired.

In the disclosed embodiment, the inner surface 52 desirably includes aplurality of first portions 60 and a plurality of second portions 62.Both the first and second portions 60, 62 are desirably arcuate orcurved and are connected to one another in an alternating, end-to-endmanner to encircle the axis 32. The first portions 60 have a convexshape and the second portions 62 have a concave shape. Each firstportion 60 defines a lobe 66 extending radially towards the axis 32. Thesecond portions 62 define spaces 68 between the lobes 66. Collectively,the lobes 66 and spaces 68 form and define a hexalobe, radially outercontour of the recess 50. Although six lobes 66 and six spaces 68 areillustrated in FIG. 4 it will be appreciated that the inner surface 52may be configured to form more or fewer lobes and/or spaces in asymmetric or asymmetric pattern in accordance with the presentinvention. Furthermore, although the recess 50 is shown in FIG. 3 ashaving a larger cross-section than the shaft 80 it will be appreciatedthat the recess may have the same or a smaller cross-section than theshaft (not shown). It should also be understood that other recess shapescould be utilized in accordance with other embodiment of the presentinvention, including oval, triangular, square, pentagonal and hexagonalshapes (and so on), which may include straight and/or curvedlongitudinal surfaces in various combinations.

As best seen in FIG. 3, a rounded corner or fillet 55 can connect theinner surface 52 to the axial end surface 42. Similarly, a fillet 57 canbe used to connect the inner surface 52 to the inner end surface 54. Theuse of fillets and similar machining techniques will desirably simplifymanufacturing and/or machining of various components, as well asdesirably reduce the opportunity for stress concentrations and/or notchsensitivity. It should be appreciated, however, that the inner surface52 may be formed into a variety of planer and/or non-planar shapes,including shapes that alternatively taper inwards and/or outwards in adirection extending towards the distal end 36 of the screw 30.

Referring to FIGS. 3 and 4, an axially extending projection 110 extendsfrom the inner end surface 54 away from the shaft 80. In thisembodiment, the projection 110 is desirably spaced entirely from theinner surface 52. The projection 110 is centered on the axis 32 but maybe offset or spaced from the axis (not shown). The projection 110 has acircular axial cross-section and a rounded side 111. The projection 110desirably tapers inwardly in a direction extending from the inner endsurface 54 towards the first end 34. The projection 110 terminates at atapered, domed or hemispherical portion or surface defining a proximalextent 112 of the projection. The projection 110 has a height H₁measured from the inner end surface 54 to the proximal extent 112. Inthe disclosed embodiment, the height H₁ is less than the depth D₁ of therecess 50, although in other embodiments the height H₁ of the projection110 may be equal to and/or greater than the depth D₁ of the recess 50(not shown).

FIGS. 5-6B illustrate one exemplary embodiment of a placement tool suchas a screwdriver 150, for use with the screw fastener 30 of the presentinvention. In this embodiment, the screwdriver 150 has a first orproximal end 154 and a second or distal end 156. The screwdriver 150extends longitudinally along an axis 152 and includes an elongated body160. A handle 162 extends proximally from the body 160. An adaptor 164having a polygonal cross-section, e.g., square or hexagonal, extendsproximally from the handle 162 along the axis 152. The adaptor 164 maybe engaged by a tool (not shown) to facilitate operation of thescrewdriver 150, or a handle or driving mechanism may be formedintegrally therewith (not shown).

Referring to FIG. 6A, the distal end 156 of the screwdriver 150 of FIG.5 desirably terminates at a post, boss or pilot 170, which desirablyengages with the fastener. The pilot 170 fits into and cooperates withthe recess 50 and projection 110 of the screw 30 such that the screw isdesirably self-centering on the screwdriver and the pilot and screw areheld together, with an engagement feature, such as a friction fit,detent-type mechanism or a positive locking-type fit, provisionallyengaging between the screw and the screwdriver. This configuration alsodesirably seats the pilot 170 within the screw 30 so as to avoid havingthe pilot slide partially out of the recess and potentially strippingsome or all of the interface between the screw and screwdriver 150.Desirably, the pilot 170 and projection 110 are sized and held totolerance so that the engagement feature between the pilot and the screw30 provides sufficient holding force to retain the screw on thescrewdriver 150, without requiring the operator to manually hold thescrew onto the screwdriver and/or limit movement and/or rotation of thescrewdriver while the screw is provisionally attached thereto.

FIGS. 6A and 6B depict one embodiment of a lower portion of the body160, which extends distally to an axial end surface 166. The pilot 170comprises a projection which extends distally from the axial end surface166. The pilot 170 desirably extends longitudinally along the axis 152and terminates at an axial end surface or “tip” 168. In variousembodiment, the pilot 170 may include a rounded or fillet portion 180extending from the axial end surface 166, the incorporation of whichwill desirably simplify manufacturing and/or machining of variouscomponents, simply insertion of the pilot 170 into the recess, anddesirably reduce the opportunity for stress concentrations and/or notchsensitivity to degrade and/or damage the tool. The pilot 170 furtherincludes a portion 182 extending from the fillet portion a distal endsurface 168. The portion 182 can have a height H₂, which can be measuredfrom the fillet portion 180 to the axial end surface 168. In variousembodiments, the height H₂ can corresponds to the depth D₁ of the recess50 in the head 40 of the screw 30, although heights H₂ that may belesser than or greater than the depth D₁ of the fastener arecontemplated herein.

The portion 182 desirably includes a series of convex lobes 174 andconcave spaces 176 between the lobes, with the lobes 174 and spaces 176shown extending parallel to the axis 152. The lobes 174 of the pilot 170are desirably sized and/or contoured to fit within the recess 50 of thefastener, desirably providing a slip fit engagement with the spaces 68in the head 40 of the screw 30. Similarly, the spaces 176 between thelobes 174 are sized and contoured to form a slip fit engagement with thelobes 66 of the screw 30. Consequently, the portion 182 has a hexalobeaxial cross-section, as disclosed herein, although various other toolshapes capable of fitting within and engaging some portion of the recess50 of the fastener could be utilized (i.e., a dual lobe or tri-lobepilot), with varying utility.

An inner surface 189 extends from the end surface 168 inwards towardsthe body 160 to define an opening 190, desirably configured to receivethe projection 110 of the fastener or screw 30. The opening 190 iscentered on the axis 152. In various embodiments, the opening 190 andprojection 110 can desirably cooperate to center the pilot 170 withinthe recess 50 by aligning the axes 32, 152 of the screw 30 andscrewdriver 150 when the two engage one another. The inner surface 189is sized, shaped and configured to provide a provisional engagementbetween the tool and fastener, which in this embodiment comprises afriction fit between the inner surface 189 and the projection 110 on thescrew 30, holding the fastener onto the tool such that a significantamount of translational and/or rotational movement can be transferredfrom the screwdriver 150 to the screw (when the pilot 170 is insertedwithin and engaged to the recess 50). Accordingly, in one exemplaryembodiment the inner surface 189 can have a frustoconical shape, thatdesirably tapers inwardly in a direction extending from the end surface168 towards the body 160, terminating at an axial end surface 191 (FIG.6B). Of course, it is contemplated that the inner surface 189 may have avariety of shapes capable of engaging with the projection in a desiredmanner, including virtually any desired shape capable of providing thedesired engagement function, e.g., cylindrical, including shapes thatprovide a friction fit with the projection 110. If desired, the innersurface 189 need not have a surface that exactly conforms to the outersurface of the projection 110.

FIGS. 7A-7C illustrate one exemplary method of using the screw 30 andscrewdriver 150 embodiments of the present invention. Although themethod illustrates implanting the screw 30 within a metacarpal boneduring a surgical procedure, it will be appreciated that the screw couldlikewise be utilized in virtually any other medical procedure requiringthe use of fasteners, including implantation into any other smallbone(s) in the body or used in a wide variety of other orthopedic andsurgical applications including spinal surgery, plating in various areasof the body, soft tissue repair, bone anchoring or biological orartificial materials other than bone. It should also be appreciated thatthe fastener or screw could be utilized in a variety of non-medicalapplications, including in virtually any industry in which fasteners arecurrently used, including manufacturing and/or construction. If desired,the fastener could be secured to virtually any material, includingmetals, polymers, plastics, ceramics, stone, aggregates, compositesand/or any other substance(s) normally fixated with fasteners.

Referring to FIG. 7A, the pilot 170 of the screwdriver 150 can bealigned with and inserted into the recess 50 in the screw 30. The axialcross-sections of the portion 182 and the recess 50 are desirablyrotationally aligned with one another relative to the axes 32, 152 toallow the pilot to be inserted into the recess 50. This rotation can beaccomplished by a user manually (i.e., by manually rotating a screw ontothe non-rotating driver bit of the tool or by rotating the tool relativeto the screw), or could be accomplished automatically using variousalignment machinery or tools. The portion 182 and the recess 50desirably help to self-center the screwdriver 150 and screw 30 tofacilitate contacting and/or connecting the inner surface 189 and theprojection 110. As noted, the portion 182 and the inner surface 52 aredesirably configured to have a slip fit engagement with one another.Consequently, the portion 182 will optimally freely pass into the recess50 once the pilot 170 and recess 50 are rotationally aligned with oneanother and the screwdriver 150 moved in the direction indicatedgenerally by the arrow A into the recess.

Further movement of the screwdriver 150 in the direction A (relative tothe screw) desirably causes the projection 110 to enter and becomeprovisionally engaged (i.e., frictionally engaged or “wedged”) with theinner surface 189. As disclosed in this embodiment, the frictionalengagement between the projection 110 and inner surface 189 forms afriction fit. The friction fit connection securely retains the screw 30on the pilot 170. In this configuration, the axial end surface 168 ofthe pilot 170 may engage the inner end surface 54 of the screw 30 or thepilot may be spaced from the inner end surface (not shown). If desired,some portion of the axial end surface 168 and/or fillet portion 180might similarly engage with the axial end surface 42 of the screw (notshown), or the axial end surface 168 may be spaced from the axial endsurface 42, as depicted in FIG. 7A. In the various embodiments, theadvantageous friction fit and/or other engagement feature between theprojection 110 and the inner surface 189 desirably permits a user of thetool (i.e., a surgeon, a machinist, an engineer, a construction worker,aircraft mechanic, etc.) to load and engage the screw with the drivertip of the tool, and subsequently freely manipulate the screw 30 on thescrewdriver 150 (which may be accomplished in a single-handed operation,if desired) without being required to manually hold the screw onto thescrewdriver.

Referring to FIG. 7B, the screw 30 and screwdriver 150 can be used toconnect and/or secure together a first and second item or work piece,which in the figure is depicted as a first and second portions 202, 204of a bone 200 having a fracture 206 therein. Once the screw 30 has beenengaged and/or is friction fit onto the tip of the screwdriver 150 thecutting tip 90 of the screw 30 can be placed on an outer surface 208 ofthe bone 200 along a desired trajectory 210 through the bone 200. Thedesired trajectory 210 may traverse the first and second portions 202,204 and the fracture 206. Rotation of the screwdriver 150 in thedirection indicated by the arrow R about the axes 32, 152 desirablycauses the cutting tip 90 to penetrate the bone 200 in a known manner.The configuration of the sharp flutes 92 and frustoconical recess 94 ofthe cutting tip 90 desirably causes the screw 30, upon rotation, toself-start and self-tap into the bone 200 along the trajectory 210.Continued rotation of the screwdriver 150 advances the screw 30 into thebone along the trajectory 210 until the axial end surface 42 of the head40 is adjacent or substantially co-planar with the outer surface 208 ofthe bone 200 (FIG. 7C). This securely fixes the screw 30 in the bone 200and desirably compresses the portions 202, 204 across the fracture 206to facilitate healing of the fracture. The surgeon may then tilt and/orpull the screwdriver 150 away from the implanted screw 30 in a directionB to desirably release the engagement feature (i.e., frictionalengagement in the disclosed embodiment) between the opening 190 and theprojection 110. Engagement of the threads 82 within the bone 200 and/orother work piece desirably allows the user to impart a desired amount offorce on the tool that imparts a separating force between the screw 30and the screwdriver 150, which desirably overcomes the engagement force(i.e., friction fit) between the screw 30 and the screwdriver 150,allowing the tool to be removed from the screw without changing theposition of the screw within the bone or other work piece and/ordisturbing the work piece in an undesired manner. In one exemplaryembodiment, the engagement force might be in the range of the weight ofthe fastener (or possibly 2, 3, 4, 5, 10 or 20 times the weight of thefastener), an ounce, a pound or more, while application of a greateramount of force than the engagement force (which may need to be appliedin a particular direction, if desired) might easily separate thefastener from the driving tool.

FIGS. 8A-20D illustrate a variety of alternative configurations forfasteners that incorporate various provisional engagement featuresbetween the fastener and a fastening tool. In FIGS. 8A-20D, similarcomponents for many features to those found in FIGS. 1-4 have been giventhe same reference numeral with the added suffix “a”, “b”, “c”, “d”, and“e”, respectively. Although not shown or specifically described in manyembodiments, it should be understood that an appropriate engagementfeature of the fastening tool (i.e., the pilot of the screwdriver 150,for example) would desirably be appropriately contoured, shaped and/orsized to the shapes of the recess and/or projection (which could includeidentical configurations or non-identical configurations capable ofengaging with corresponding features) in each of the alternativeconfigurations of FIGS. 8A-20D. In various described embodiments, acorresponding opening inner surface and screw head projection could bedesigned to provide appropriate provisional engagement structures andtheir related relationships with each other, such as a friction fit, toprovide similar or the same advantages as the screw 30 and screwdriver150 of FIGS. 1-6B. Any of the screw configurations illustrated anddescribed in the various figures contained herein may be configured forsecuring to any work piece and/or the aforementioned structures, e.g., ametal, polymer, plastic, wood, bone or other biological tissue.

Referring to the embodiment of FIGS. 8A and 8B, a projection 110 a canhave a polygonal cross-section. In one example, the projection 110 a canhave a square or rectangular cross-section. The projection 110 a hasfour sides 111 a. It will be appreciated, however, that the projection110 a may constitute a different polygonal shape, e.g., oval, circular,triangular, hexagonal, etc. The projection 110 a can taper continuouslyin a radially inward direction relative to the axis 32 a as theprojection extends from the inner end surface 54 a towards the axial endsurface 42 a. Each of the sides 111 a has a planar configuration but mayalternatively have arcuate or curved contours (not shown). In thisembodiment, the projection 110 a extends axially beyond the axial endsurface 42 a of the head 40 a. In other words, the height H₃ of theprojection 110 a measured from the inner end surface 54 a to theproximal extent 112 a is greater than the depth D₁ of the recess 50 a.The height H₃ of the projection 110 a may, however, be equal to or lessthan the depth D₁ of the recess 50 (not shown).

In various embodiments, it may be desirable that the projection includea number and/or distribution of external features (i.e., externalsurfaces and/or shapes) that match and/or correspond to the opposinginner surfaces of the recess (i.e., three or six projecting surfacesthat match a hexalobe or hexagonal recess) to allow for the tool toassume a variety of rotational orientation relative to the fastener.Alternatively, the projection may provide for a limited number oforientations and/or only a single orientation of the tool relative tothe fastener, if desired. In various embodiments, the projection may beprovided with a particularized shape and/or size that corresponds to aspecific use and/or fastening tool, such as where high-strengthfasteners of a specific design and/or particularized fastening tools aredesired for a particular application (i.e., aircraft fasteners andrivets). Similarly, the tool may include a feature that provides aparticular rotational force that corresponds to a specific fastener—theprojection could be particularized to only accept the desired torquetool or custom designed to incorporate a specific provisional engagementforce. The projection may include user-defined engagement features todefine the desired provisional engagement force or disengagement force.For example, if a projection includes a taper, the taper angle may becustomized for light or heavy torque transmission loads. The taper anglemay be adjusted to obtain an increased “frictional coupling,” wedge orbinding effect due to the friction across the entire surface area of theinterface between the screwdriver or fastening tool and the screw andprojection. Also, such custom engagement features may be designed toaffect the provisional disengagement force. In various embodiment thedisengagement force can be different than the engagement force.Potentially, the disengagement force may be so high that it may requirea removal tool (i.e., a “drift”, a drift punch, or a wedge, etc.) or aninternal removal feature within the fastening tool. If desired, thetorque tool could comprise a replaceable and/or modular bit or otherdriving feature that desirably fits into the fastening tool (i.e., aremovable torque-limiting chuck).

Although not shown, it will be appreciated that an appropriatescrewdriver 150 for use with the screw 30 a of FIGS. 8A and 8B could beconfigured to cooperate with the screw 30 a in a similar manner to howthe screwdriver 150 cooperates with the screw 30 of FIGS. 2-4. Inparticular, with the screw 30 a of FIGS. 8A and 8B, the lobes 174 of thepilot 170 would desirably be sized and contoured to have a slip fit withthe spaces 68 a in the head 40a of the screw 30 a. The spaces 176between the lobes 174 could be sized and contoured to form a slip fitwith the lobes 66 a of the screw 30 a. Consequently, the portion 182could have a hexalobe axial cross-section, similar to the hexalobe axialcross-section of the recess 50 a.

The inner surface 189 would desirably be sized and contoured to engagewith and/or form a provisional engagement and/or friction fit with theprojection 110 a on the screw 30 a. More specifically, the inner surface189 may have a corresponding polygonal cross-section which included afrustoconical shape that tapers inwardly in a direction extending fromthe axial end surface 168 towards the body 160. The axial cross-sectionand taper of the inner surface 189 could be such that the inner surfaceand projection 110 a desirably form a friction fit with one anotherwithin the recess 190, which may include a series of corresponding flatinner surfaces and/or a curved or rounded inner surface(s), if desired.The inner surface 189 may be configured to allow the pilot 170 to abutthe inner end surface 54 a or the pilot may be spaced from the innersurface when the provisional engagement and/or friction fit is formed.

Referring to FIGS. 9A and 9B, another embodiment of the fastener couldinclude a head 40 b of the screw 30 b including a projection 110 b and alobed inner surface 52 b that defines the recess 50 b. The projection110 b can have a polygonal axial cross-section with a plurality ofconcave sides 111 b. In one example, the projection 110 b can have thesame number of sides 111 b as the number of lobes 66 b defined by theinner surface 52 b. It will be appreciated, however, that the projection110 b may have more or fewer sides 111 b than the number of lobes 66 b.Each side 111 b may be radially aligned with a corresponding firstportion 60 b or may be radially offset from the first portions (notshown).

The projection 110 b desirably tapers in a radially inward directionrelative to the axis 32 b as the projection extends from the inner endsurface 54 b towards the axial end surface 42 b. Each of the taperingsides 111 b can be concave. The proximal extent 112 b of the projection110 b can have the same radius of curvature as the axial end surface 42b. In the depicted embodiment, the projection 110 b extends axiallybeyond the axial end surface 42 b of the head 40 b. In other words, theheight H₄ of the projection 110 b measured from the inner end surface 54b to the proximal extent 112 b is greater than the depth D₁ of therecess 50 b. In alternative embodiments, however, the height H₄ of theprojection 110 b may be equal to or less than the depth D₁ of the recess50 b (not shown).

Although not shown, the lobes 174 of a corresponding screwdriver 150that can cooperate with the screw 30 b would desirably be sized andcontoured to have a slip fit with the spaces 68 b in the head 40 b ofthe screw 30 b. The spaces 176 between the lobes 174 can be sized andcontoured to form a slip fit with the lobes 66 b of the screw 30 b.Consequently, the portion 182 has a hexalobe axial cross-section. Theinner surface 189 can be sized and contoured to form a provisionalengagement and/or friction fit with the projection 110 b on the screw 30b. More specifically, the inner surface 189 has a polygonal axialcross-section with convex sides (not shown). The inner surface 189 cantaper inwardly in a direction extending from the axial end surface 168towards the body 160. The axial cross-section and taper of the innersurface 189 is such that the inner surface and projection 110 b form aprovisional engagement and/or friction fit with one another within therecess 190. The inner surface 189 may be configured to allow the pilot170 to contact and/or “bottom out” within the recess 50 b or the pilotmay be spaced from the inner end surface 54 b when the friction fit isformed.

Referring to FIGS. 10A and 10B, another embodiment of the fastener couldinclude an inner surface 52 c of the screw 30 c that has substantiallyplanar surfaces 53, desirably forming a hexagonal shape about the axis32 c. Although six planar surfaces 53 are illustrated it will beappreciated that the inner surface 52 c may include more or fewer planarsurfaces defining any desired polygonal shape. The planar surfaces 53extend parallel to the axis 32 c but may alternatively taper inwards ina direction extending toward the inner end surface 54 c (not shown).

In this embodiment, the projection 110 c has a frustoconical shape,which can function particularly well to facilitate alignment andpositioning of the driver within the recess. The projection 110 ccontinuously tapers in a radially inward direction relative to the axis32 c as the projection extends from the inner end surface 54 c towardsthe axial end surface 42 c. The projection 110 c extends axially beyondthe axial end surface 42 c of the head 40 c—in other words, the heightH₅ of the projection 110 c measured from the inner end surface 54 c tothe proximal extent 112 c is greater than the depth D₁ of the recess 50c. This arrangement can be particularly useful to a user of the fixationsystem, in that during “loading” of the fixation screw onto the drivingtool, the projection 110 c can be partially inserted into the opening190 (with the projection tip desirably smaller than the opening and suchinsertion visually verifiable) and the screw rotated to align the recesswith the lobes 174 of the driving tool, and then the screw can be fullyseated onto the tool. Of course, in alternative embodiments the heightH₅ of the projection 110 c may be equal to or less than the largestdepth D₁ of the recess 50 c (not shown).

Although not shown, the lobes 174 of the screwdriver 150 that cooperatewith the screw 30 c can be sized and contoured to have a slip fit withthe planar surfaces 53 in the head 40 c of the screw 30 c. Consequently,the portion 182 has a hexagonal axial cross-section similar to thehexagonal axial cross-section of the recess 50 c. The inner surface 189can be sized and contoured to form a provisional engagement and/orfriction fit with the projection 110 c on the screw 30 c. Morespecifically, the inner surface 189 has a shape that cooperates with thefrustoconical shape of the projection, which may include a correspondingfrustoconical shape for the inner surface that tapers inwardly in adirection extending from the axial end surface 168 towards the body 160.The axial cross-section and taper of the inner surface 189 is such thatthe inner surface and projection 110 c form a provisional engagementand/or friction fit with one another within the recess 190. The innersurface 189 may be configured to allow the pilot 170 to bottom outwithin the recess 50 c or the pilot may be spaced from the inner endsurface 54 c when the friction fit is formed.

Referring to FIGS. 11A and 11B, another embodiment of the fastener couldinclude an inner surface 52 d and projection 110 d of the screw 30 dthat desirably cooperate to form a plurality of polygonal recesses 50 din the head 40 d of the screw 30 d. More specifically, six planarsurfaces 53 d of the inner surface 52 d can cooperate with theprojection 110 d and the inner end surface 54 d to form a pair oftrapezoidal recesses 50 d in the head 40 d of the screw 30 d. It will beappreciated, however, that the head 40 d may include any number ofprojections 110 d in order to form a desired number of recesses 50 d.

In this embodiment, the projection 110 d desirably extendslongitudinally along the axis 32 d and radially between opposing sidesof the inner surface 52 d. The projection 110 d extends axially beyondthe axial end surface 42 d of the head 40 d. In other words, the heightH₆ of the projection 110 d measured from the inner end surface 54 d tothe proximal extent 112 d is greater than the depth D₁ of the recess 50d. The height H₆ of the projection 110 d may, however, be equal to orless than the depth D₁ of the recess 50 d (not shown).

Although not shown, it will be appreciated that a pilot 170 for ascrewdriver 150 configured to engage with and/or form a provisionalengagement and/or friction fit with the screw 30 d can include abifurcated or multi-section tip configuration to accommodate one or moreof each discrete recess 50 d. In other words, such a pilot 170 coulddesirably have multiple, discrete portions corresponding in shape(s) andnumber with the shape(s) and number of recesses 50 d in the screw 30 d.The pilot 170 in this embodiment could form a provisional engagementand/or friction fit with the projection 110 d and a slip fit with theplanar surfaces 53 d of the recess 50 d.

Referring to FIGS. 12A and 12B, another embodiment of the fastener couldinclude a head 40 e of the screw 30 e incorporating a projection 110 eand a lobed inner surface 52 e that defines the recess 50 e. Theprojection 110 e in this embodiment has a domed or hemispherical shape.The projection 110 e extends from the axial end surface 54 e to aproximal extent 112 e along the axis 32 e. The projection 110 e has aheight H₇ measured from the axial end surface 54 e to the proximalextent 112 e. The height H₇ is less than the depth D₁ of the recess 50e. The height H₇ of the projection 110 e may, however, be equal to orgreater than the depth D₁ of the recess 50 e (not shown).

Although not shown, the lobes 174 of the screwdriver 150 that couldcooperate with the screw 30 e would desirably be sized and contoured tohave a slip fit with the spaces 68 e in the head 40 e of the screw 30 e.The spaces 176 between the lobes 174 can be sized and contoured to forma slip fit with the lobes 66 e of the screw 30 e. Consequently, theportion 182 has a hexalobe axial cross-section that is similar to thehexalobe axial cross-section of recess 50 e. The inner surface 189 canbe sized and contoured to engage with and/or form a provisionalengagement and/or friction fit with the projection 110 e on the screw 30e. More specifically, the inner surface 189 can have a frustoconicalshape (not shown). The inner surface 189 could taper inwardly in adirection extending from the axial end surface 168 towards the body 160.The axial cross-section and taper of the inner surface 189 is such thatthe inner surface and projection 110 e form a provisional engagementand/or friction fit with one another within the recess 190. The innersurface 189 may be configured to allow the pilot 170 to bottom outwithin the recess 50 e or the pilot may be spaced from the inner endsurface 54 e when the provisional engagement and/or friction fit isformed.

Referring to FIGS. 13A through 13D, another embodiment of the fastenercould include a projection 110 f having a circular axial cross-sectionand a generally frustoconical shape. It will be appreciated, however,that the projection 110 f may have a variety of different axialcross-sections and/or shapes. The projection 110 f can tapercontinuously in a radially inward direction relative to the axis 32 f asthe projection extends from the inner end surface 54 f towards the axialend surface 42 f. In the disclosed embodiment, the projection 110 fextends axially beyond the axial end surface 42 f of the head 40 f—inother words, the height H₅ of the projection 110 f measured from theinner end surface 54 f to the proximal extent 112 f is greater than thedepth D₁ of the recess 50 f. The height H₅ of the projection 110 f may,however, be equal to or less than the depth D₁ of the recess 50 f (notshown).

In this embodiment, a bore or passage 113 f is formed in the projection110 f. The passage 113 f desirably extends from the proximal extent 112f towards the second end 36 f of the screw 30 f. In one example, thepassage 113 f extends through the entire screw 30 f, creating a fullycannulated screw (i.e., which may have particularly utility inwire-guided medical surgical procedures or similar applications).Alternatively, the passage 113 f may extend through a portion or all ofthe projection 110 f or terminate at a position along the shaft 80 f(not shown). The passage 113 f desirably has a circular axialcross-section and a cylindrical shape, although various alternativeshapes may be incorporated, if desired. The passage 113 f is depictedcentered on the axis 32 f.

Although not shown, it should be appreciated that a fixation tool, suchas a screwdriver 150, for use with the fastener or screw 30 f of FIGS.13A and 13B could be configured to cooperate with the screw 30 f in asimilar manner to how the screwdriver 150 cooperates with the screw 30of FIGS. 2-4. In particular, with the screw 30 f of FIGS. 13A and 13B,the lobes 174 of the pilot 170 could be sized and contoured to engagewith and/or have a slip fit with the spaces 68 f in the head 40 f of thescrew 30 f. The spaces 176 between the lobes 174 would desirably besized and contoured to form a slip fit with the lobes 66 f of the screw30 f. Consequently, the portion 182 could have a hexalobe axialcross-section similar to the hexalobe axial cross-section of the recess50 f.

In this embodiment, the inner surface 189 of the fixation tool could besized and contoured to engage with the projection 110 f on the screw 30f (i.e., desirably forming a friction fit or other engagement feature).More specifically, the inner surface 189 may have a circular axialcross-section and a frustoconical shape that tapers inwardly in adirection extending from the axial end surface 168 towards the body 160.The axial cross-section and taper of the inner surface 189cou1d be suchthat the inner surface and projection 110 f engage with and/or form aprovisional engagement and/or friction fit with one another within therecess 190. The inner surface 189 may be configured to allow the pilot170 to abut the inner end surface 54 f or the pilot may be spaced fromthe inner surface when the provisional engagement and/or friction fit isformed.

If desired, the driving tool may similarly incorporate alongitudinally-extending opening or cannulation (not shown) which couldbe used to follow a guide wire with the fastener and attached tool.

In another alternative embodiment, a projection (not shown) may extendfrom the axial end surface 191 of the fixation tool, with the projectionsized and/or shaped to fit into and/or cooperate with the passage 113fin the screw 30 f to assist the user in aligning the screwdriver 150 andscrew 30 f along the axes 32 f, 152. To this end, this projection mayhave a circular axial cross-section and may taper inwardly in adirection extending distally along the axis 152, if desired.

Referring to FIGS. 14A through 14E, another embodiment of a fastenercould include a projection 110 g having a circular axial cross-sectionand a generally cylindrical shape. It will be appreciated, however, thatthe projection 110 g may have a variety of different axialcross-sections, heights and/or shapes. In this embodiment, theprojection 110 g desirably extends axially beyond the axial end surface42 g of the head 40 g. In other words, the height H₉ of the projection110 g measured from the inner end surface 54 g to the proximal extent112 g is greater than the depth D₁ of the recess 50 g. The height H₉ ofthe projection 110 g may, however, be equal to or less than the depth D₁of the recess 50 g (not shown).

A bore or passage 113 g can be formed in the projection 110 g. In thisembodiment, the passage 113 g comprises a transverse slot that has arectangular axial cross-section and extends from the proximal extent 112g towards the second end 36 g of the screw 30 g. The passage 113 g cantaper inwardly in a direction extending towards the second end 36 g ofthe screw 30 g. The passage 113 g terminates at an inner end surface 115g within the projection 110 g, although the inner end surface mayalternatively be positioned within the body 80 g (not shown). The innerend surface 115 g may therefore be substantially coplanar with the innerend surface 54 g or spaced axially from the inner end surface in theproximal or distal direction along the axis 32 g. As depicted, thepassage 113 g extends radially from the axis 32 g through the entireprojection 110 g and divides the proximal end of the projection into twodistinct portions. If compressed together, the two distinct portions maycreate a force directed radially outward when engaged with the pilot,desirably creating a higher provisional engagement force. It will beappreciated that the passage 113 g may be configured shallower withinthe recess, may create thicker and/or thinner projections and/or may beconfigured to divide the projection 110 g into more or fewer distinctportions (i.e., using multiple slots, etc.). Desirably, the passage 113g will be centered on the axis 32 g, which desirably allows the portionsof the projection 110 g to radially deflect relative to the axis and toone another.

Although not shown, it will be appreciated that an appropriate drivingtool or screwdriver 150 for use with the screw 30 g of FIGS. 14A and 14Bcould be configured to cooperate with the screw 30 g in a similar mannerto how the screwdriver 150 cooperates with the screw 30 of FIGS. 2-4. Inparticular, with the screw 30 g of FIGS. 14A and 14B, the lobes 174 ofthe pilot 170 are sized and contoured to have a slip fit with the spaces68 g in the head 40 g of the screw 30 g. The spaces 176 between thelobes 174 are sized and contoured to form a slip fit with the lobes 66 gof the screw 30 g. Consequently, the portion 182 has a hexalobe axialcross-section similar to the hexalobe axial cross-section of the recess50 g.

The inner surface 189 of the driving tool can be sized and contoured toengage with and/or form a friction fit with the projection 110 g on thescrew 30 g. More specifically, the inner surface 189 may have a circularaxial cross-section and may incorporate a generally cylindrical and/orfrustoconical shape (i.e., including a frustoconical shape that tapersinwardly in a direction extending from the axial end surface 168 towardsthe body 160). The axial cross-section and optional taper of the innersurface 189 are such that the inner surface and projection 110 g willdesirably provisionally engage with and/or form a friction fit with oneanother within the recess 190. For example, the inner surface 189 may besized to deflect the portions of the projection 110 g inward towards theaxis 32 g such that the resistance of the projection portions to thedeflection causes and/or enhances the provisional engagement and/orfriction fit between the projection and the inner surface. The innersurface 189 may be configured to allow the pilot 170 to abut the innerend surface 54 g or the pilot may be spaced from the inner surface whenthe provisional engagement and/or friction fit is formed.

In various alternative embodiments, a projection or other feature (notshown) may be disposed within the opening 190, extending from the axialend surface 191, and be sized and shaped for cooperating with thepassage 113 g in the screw 30 g. If desired, the projection could engagewith the passage 113 g and potentially help align the screwdriver 150and screw 30 g along the axes 32 g, 152. To this end, this projectionmay have a rectangular axial cross-section and may taper inwardly in adirection extending distally along the axis 152. In other embodiments,the projection might selectively extend into the passage 113 g anddesirably interfere with deflection or other movement of theprojections, and in some embodiments might form a “locking feature”which selective locks and/or unlocks the provisional engagement featurebetween the screw and the driving tool.

Referring to FIGS. 15A-15D, another embodiment of a fastener couldinclude a head 40 h incorporating a series of radially extendingpassages 117 h, which could provisionally engage with and/or provide aprovisional engagement and/or friction fit with the screwdriver 150.Each passage 117 h could extend radially through one of the concaveportions 62 h from the inner surface 52 h to the rounded surface 44 h.It will be understood that any number of passages 117 h may be providedthrough any number of concave portions 62 h.

In this embodiment, each passage 117 h can also extends axially from theend surface 42 h of the head 40 h towards the inner surface 54 h,terminating at an inner end surface 118 h and dividing the head into sixdistinct portions. It will be appreciated that the passages 117 h may bealternatively configured to divide the head 40 h into more or fewerdistinct portions. If desired, the passages 117 h may extend lesserand/or greater depths within the head 40 h to allow portions of the headto deflect relative to each other.

Each disclosed passage 117 h can have a substantially rectangular axialcross-section that tapers inwardly in a direction extending from the endsurface 42 h towards the inner surface 118 h. The passages 117 h canhave a depth or height H₁₀ measured from the inner end surface 118 h tothe end surface 42 h that is less than the depth D₁ of the recess 50 h.The height H₁₀ of the passages 117 h may, however, be equal to orgreater than the depth D₁ of the recess 50 h such that the concaveportions 62 h are substantially or entirely omitted. The passages 117 hare shown symmetrically arranged about the axis 32 h, but mayalternatively be asymmetrically arranged about the axis (not shown). Thepassages 117 h are shown identical to one another, but may alternativelybe different from one another (not shown).

Although not shown, it will be appreciated that a driving tool orscrewdriver 150 for use with the screw 30 h of FIGS. 15A-15C could beconfigured to cooperate with the screw 30 h in a similar manner to howthe screwdriver 150 cooperates with the screw 30 of FIGS. 2-4. Inparticular, with the screw 30 h of FIGS. 15A-15C, the spaces 176 betweenthe lobes 174 can be sized and contoured to form a slip fit with thelobes 66 h of the screw 30 h. Consequently, the portion 182 can have ahexalobe axial cross-section similar to the hexalobe axial cross-sectionof the recess 50 h. Alternatively, a standard or universal screwdriveror driving tool might be used to manipulate the screw (i.e., a flat-heador Philips-head screwdriver), if desired.

The pilot 170 of the driving tool will desirably include structure sizedand contoured to engage with and/or form a provisional engagement and/orfriction fit with the passages 117 h on the screw 30 h. Morespecifically, one or more projections may extend radially outward fromthe convex lobes 174 for mating with one or more of the passages 117 h.Each projection on the lobes 174 can have a rectangular axialcross-section and frustoconical shape that tapers outwardly in adirection extending from the axial end surface 168 towards the body 160.The axial cross-section and taper of the projections on the lobes 174can be formed such that one or more of the projections and passages 117h form a provisional engagement and/or friction fit with one another. Ifthe portions of the head 40 h are deflectable relative to one another,the resistance to deflection of the head portions by the inner surface189 can further enhance the engagement and/or friction fit. Theprojections on the lobes 174 may be configured to allow the pilot 170 toabut the inner end surface 54 h or the pilot may be spaced from theinner surface when the provisional engagement and/or friction fit isformed.

Referring to FIGS. 16A through 16D, another embodiment of a fastenercould include a head 40 i of the screw 30 i is similar to the head 40 bof the screw 30 b of FIGS. 9A and 9B. The recess 50 i and projection 110i of the screw 30 i could be similar to the recess 50 b and projection110 b of the screw 30 b. The projection 110 i can have a circular axialcross-section and a generally frustoconical shape and extends axiallybeyond the axial end surface 42 i of the head 40 i. In other words, theheight H₁₁ of the projection 110 i measured from the inner end surface54i to the proximal extent 112 i is greater than the depth D₁ of therecess 50 i. The height H₁₁ of the projection 110 i may, however, beequal to or less than the depth D₁ of the recess 50 i (not shown).

In this embodiment, the projection 40 i on the screw 30 i furtherincludes a bore or passage 113 i extending from the proximal extent 112i towards the second end 36 i of the screw 30 i. In one example, thepassage 113 i extends through the entire screw 30 i. Alternatively, thepassage 113 i may extend through a portion or all of the projection 110i or terminate at a position within the head and/or along the shaft 80 i(not shown). The passage 113 i can have a circular axial cross-sectionand a cylindrical shape, although various other shapes known in the artcould be incorporated with varying levels of utility. As shown, thepassage 113 i can be centered on the axis 32 i.

Although not shown, it will be appreciated that a driving tool orscrewdriver 150 for use with the screw 30 i of FIGS. 16A and 16B couldbe configured to cooperate with the screw 30 i in a similar manner tohow the screwdriver 150 cooperates with the screw 30 of FIGS. 2-4. Thelobes 174 of the screwdriver 150 that cooperate with the screw 30 i canbe sized and contoured to engage with and/or have a slip fit with thespaces 68i in the head 40 i of the screw 30 i. The spaces 176 betweenthe lobes 174 are sized and contoured to engage with and/or form a slipfit with the lobes 66i of the screw 30 i. Consequently, the portion 182can incorporate a hexalobular cross-section.

The inner surface 189 of the pilot 170 of a corresponding driving toolcan be sized and contoured to engage with and/or form a friction fitwith the projection 110 i on the screw 30 i. More specifically, theinner surface 189 can have a polygonal axial cross-section with convexsides (not shown). If desired, the inner surface 189 can taper inwardlyin a direction extending from the axial end surface 168 towards the body160. The axial cross-section and taper of the inner surface 189 can besuch that the inner surface and projection 110 i engage with and/or forma friction fit with one another within the recess 190. The inner surface189 may be configured to allow the pilot 170 to bottom out within therecess 50 i or the pilot may be spaced from the inner end surface 54 iwhen the provisional engagement and/or friction fit is formed.

In various alternative embodiments, a projection may extend from theaxial end surface 191 and be sized and shaped for cooperating with thepassage 113 i in the screw 30 i to help align the screwdriver 150 andscrew 30 i along the axes 32 i, 152. To this end, this projection mayhave a circular axial cross-section and a cylindrical shape.

Referring to FIGS. 17A through 17D, another embodiment of a fastenercould include a head 40 j of the screw 30 j incorporating featuressimilar to those of the head 40 g of the screw 30 g of FIGS. 14A and14B. The recess 50 j and projection 110 j of the screw 30 j cantherefore be similar to the recess 50 g and projection 110 g of thescrew 30 g. In this embodiment, the projection 110 j could extendlongitudinally beyond the axial end surface 42 j of the head 40 j. Inother words, the height H₁₂ of the projection 110 j measured from theinner end surface 54 j to the proximal extent 112 j can be greater thanthe depth D₁ of the recess 50 j. The height H₁₂ of the projection 110 jmay, however, be equal to or less than the depth D₁ of the recess 50 j(not shown).

In this embodiment, the passage 113 j in the projection 110 j has anx-shaped axial cross-section and extends from the proximal extent 112 jtowards the second end 36 j of the screw 30 j. The passage 113 jdesirably extends substantially parallel to the axis 32 j whileextending towards the second end 36 j of the screw 30 j. The passage 113j desirably terminates at an inner end surface 115 j within theprojection 110 j, although the inner end surface may alternatively bepositioned in other locations with the head and/or within the body 80 j(not shown). The inner end surface 115 j may therefore be substantiallycoplanar with the inner end surface 54 j or spaced axially from theinner end surface in the proximal or distal direction along the axis 32j.

The passage 113 j can extend radially from the axis 32 j, through theentire projection 110 j (and/or some portions thereof) and divides theprojection into four distinct portions. It will be appreciated that thepassage 113 j may be configured to divide the projection 110 j into moreor fewer distinct portions. If compressed together, the four distinctportions may create a force directed radially outward when engaged withthe pilot creating a higher provisional engagement force. If desired,the passage 113 j can desirably be centered on the axis 32 j and theremoval of the material (and amount of material removed) desirablyallows the portions of the projection 110 j to deflect to varyingdegrees relative to each other.

Although not shown, it will be appreciated that a driving tool or thescrewdriver 150 for use with the screw 30 j of FIGS. 17A and 17B couldbe configured to cooperate with the screw 30 j in a similar manner tohow the screwdriver 150 cooperates with the screw 30 of FIGS. 2-4. Inparticular, with the screw 30 j of FIGS. 17A and 17B, the lobes 174 ofthe pilot 170 can be sized and contoured to have a slip fit with thespaces 68 j in the head 40 j of the screw 30 j. The spaces 176 betweenthe lobes 174 can be sized and contoured to form a slip fit with thelobes 66 j of the screw 30 j. Consequently, the portion 182 can have ahexalobe axial cross-section similar to the hexalobe axial cross-sectionof the recess 50 j.

In a corresponding driving tool or screwdriver, the inner surface 189can be sized and contoured to engage with and/or form a provisionalengagement and/or friction fit with the projection 110 j on the screw 30j. More specifically, the inner surface 189 might have a circular axialcross-section and/or a cylindrical or frustoconical shape (i.e., thattapers inwardly in a direction extending from the axial end surface 168towards the body 160). The axial cross-section and inner surface 189 canbe sized and configured such that the inner surface and projection 110 jdesirably provisionally engage with each other (i.e., optionallyincluding a friction fit with one another) within the recess 190. Forexample, the inner surface 189 of the opening 190 might be sizedslightly smaller than the outer diameter of the projection, such that itdeflects the portions of the projection 110 j inward towards the axis 32j, desirably so that the resistance of the projection portions to thedeflection can physically engage the components and/or enhance anyprovisional engagement and/or friction fit between the projection andthe inner surface. The inner surface 189 may be configured to allow thepilot 170 to abut the inner end surface 54 j or the pilot may be spacedfrom the inner surface when the provisional engagement and/or frictionfit is formed.

If desired, a projection may extend from the axial end surface 191 andbe sized and shaped for cooperating with the passage 113 j in the screw30 j to help align the screwdriver 150 and screw 30 j along the axes 32j, 152. To this end, this projection may have an x-shaped axialcross-section and be centered on the axis 152. In other embodiments, theprojection might selectively extend into the passage 113 j and desirablyinterfere with deflection or other movement of the projections, and insome embodiments might form a “locking feature” which selective locksand/or unlocks the provisional engagement feature between the screw andthe driving tool.

Referring to FIGS. 18A through 18D, another embodiment of a fastenercould incorporate a projection 110 k having a first portion 121 k with acylindrical shape and a second portion 123 k having a spherical shape.The first portion 121 k can desirably extend along the axis 32 k, awayfrom the inner end surface 54 k. The second portion 123 k can extendalong the axis 32 k from the first portion 121 k, away from the innerend surface 54 k. The largest axial cross-section of the second portion123 k can be larger than the axial cross-section of the first portion121 k, thereby forming an undercut 124 k between the first and secondportions. The height H₁₃ of the projection 110 k measured from the innerend surface 54 k to the proximal extent can be less than the depth D₁ ofthe recess 50 k. Alternatively, the height H₁₃ of the projection 110 kmay be equal to or greater than the depth D₁ of the recess 50 k (notshown).

In this embodiment, the passage 113 k in the projection 110 k on thescrew 30 k can have an x-shaped axial cross-section, which extends fromthe proximal extent towards the second end 36 k of the screw 30 k. Thepassage 113 k extends substantially parallel to the axis 32 k whileextending towards the second end 36 k of the screw 30 k. The passage 113k can terminate at an inner end surface 115 k within the projection 110k, although the inner end surface may alternatively be positioned withinthe body 80 k (not shown). The inner end surface 115 k may therefore besubstantially coplanar with the inner end surface 54 k or spaced axiallyfrom the inner end surface in the proximal or distal direction along theaxis 32 k.

As shown, the passage 113 k extends the entire length of the projection110 k. The passage 113 k extends radially from the axis 32 k through theentire projection 110 k and desirably divides the projection into somenumber of distinct portions, which in this embodiment is four distinctportions. It will be appreciated that the passage 113 k may beconfigured to divide the projection 110 k into more or fewer distinctportions. If desired, the passage 113 k can be centered on the axis 32 kor can be off-centered. The passage desirably allows the portions of theprojection 110 k to radially deflect relative to the axis and/or oneanother, as well as create a force directed radially outward while theprojections are compressed during their engagement with the pilot,potentially creating a higher provisional engagement force, if desired.Furthermore, the distinct portions in combination with the projectionundercut 124 k can significantly increases the provisional engagementforce, if desired. Such projection undercut 124 k may also provide anaudible or tactile feedback, such as a click that confirms that theprovisional engagement has occurred.

Although not shown, it will be appreciated that the screwdriver 150 foruse with the screw 30 k of FIGS. 18A and 18B could be configured tocooperate with the screw 30 k in a similar manner to how the screwdriver150 cooperates with the screw 30 of FIGS. 2-4. In particular, with thescrew 30k of FIGS. 18A and 18B, the lobes 174 of the pilot 170 are sizedand contoured to have a slip fit with the spaces 68 k in the head 40 kof the screw 30 k. The spaces 176 between the lobes 174 are sized andcontoured to form a slip fit with the lobes 66 k of the screw 30 k.Consequently, the portion 182 has a hexalobe axial cross-section similarto the hexalobe axial cross-section of the recess 50 k.

For the corresponding driving tool, the inner surface 189 of the opening190 can be sized and contoured to engage with and/or form a friction fitwith the projection 110 k on the screw 30 k. More specifically, theinner surface 189 may have a circular axial cross-section and afrustoconical shape that tapers inwardly in a direction extending fromthe axial end surface 168 towards the body 160. The axial cross-sectionand taper of the inner surface 189 are such that the inner surface andprojection 110 k, more specifically the spherical second portion 123 k,can engage with and/or form a provisional engagement and/or friction fitwith one another within the recess 190. For example, the inner surface189 may be sized to deflect the portions of the projection 110 k inwardtowards the axis 32 k such that the resistance of the projectionportions to the deflection enhances the provisional engagement and/orfriction fit between the projection and the inner surface. The undercut124 k facilitates deflection of the projection 110 k portions by theinner surface 189 and therefore further helps to enhance the provisionalengagement and/or friction fit. The inner surface 189 may be configuredto allow the pilot 170 to abut the inner end surface 54 k or the pilotmay be spaced from the inner surface when the provisional engagementand/or friction fit is formed. Alternatively, the inner surface 189 mayinclude a notched or detent section within the opening 190, with aportion of the opening 190 sized to deflect the portions of theprojection 110 k inward towards the axis 32 k. When compressed, portionsof the projection 110 k can create a force directed radially outward,when engaging with the pilot, potentially creating a higher provisionalengagement force. This action can allow the deflected projectionportions to “snap back” or resume some portion of their originalposition when fully seated within the opening 190 (with some portion ofthe second portion 123K sitting within the detent or groove and/ordesirably provisionally mechanically “locking” the fastener to thedriving tool. If desired, this “locking” action could be accompanied byan audible “click” and/or tactile feedback that such provisionalengagement has occurred. Furthermore, the distinct portions incombination with the projection undercut 124 k can significantlyincrease the provisional engagement force, if desired.

If desired, a projection may extend from the axial end surface 191 andbe sized and shaped for cooperating with the passage 113 k in the screw30 k to help align the screwdriver 150 and screw 30 k along the axes 32k, 152. To this end, this projection may have an x-shaped, t-shaped or1-shaped axial cross-section and be centered on the axis 152. In otherembodiments, the projection might selectively extend into the passage113 k and desirably interfere with deflection or other movement of theprojections, and in some embodiments might form a “locking feature”which selective locks and/or unlocks the provisional engagement featurebetween the screw and the driving tool.

Referring to FIGS. 19A through 19D, another embodiment of a fastenercould incorporate a projection 110 m which comprises a first portion 121m having a cylindrical shape and a second portion 123 m having agenerally frustoconical shape. The first portion 121 m can extend alongthe axis 32 m away from the inner end surface 54 m. The second portion123 m can extend along the axis 32 m from the first portion 121 m awayfrom the inner end surface 54 m. The largest axial cross-section of thesecond portion 123 m may be larger than the axial cross-section of thefirst portion 121 m, thereby forming an undercut 124 m between the firstand second portions, with the undercut being flat, angled and/orrounded, as desired. The height H₁₄ of the projection 110 m measuredfrom the inner end surface 54 m to the proximal extent is less than thedepth D₁ of the recess 50 m, although the height H₁₄ of the projection110 m may be equal to or greater than the depth D₁ of the recess 50 m(not shown).

The passage 113 m in the projection 110 m on the screw 30 m can have anx-shaped axial cross-section and extend from the proximal extent towardsthe second end 36 m of the screw 30 m. The passage 113 m can extendsubstantially parallel to the axis 32 m while extending towards thesecond end 36 m of the screw 30 m. The passage 113 m terminates at aninner end surface 115 m within the projection 110 m, although the innerend surface may alternatively be positioned within the body 80 m or inother locations (not shown). The inner end surface 115 m may thereforebe substantially coplanar with the inner end surface 54 m or spacedaxially from the inner end surface in the proximal or distal directionalong the axis 32 m.

As shown, the passage 113 m extends the entire length of the projection110 m, although the passage may extend through less of the projection,if desired. The passage 113 m extends radially from the axis 32 mthrough the entire projection 110 m and divides the projection into fourdistinct portions. It will be appreciated that the passage 113 m may beconfigured to divide the projection 110 m into more or fewer distinctportions. In any case, the passage 113 m can be centered on the axis 32m and allows the portions of the projection 110 m to radially deflectrelative to the axis and one another.

Although not shown, it will be appreciated that the screwdriver 150 foruse with the screw 30 m of FIGS. 19A and 19B could be configured tocooperate with the screw 30 m in a similar manner to how the screwdriver150 cooperates with the screw 30 of FIGS. 2-4. In particular, with thescrew 30 m of FIGS. 19A and 19B, the lobes 174 of the pilot 170 could besized and contoured to have a slip fit with the spaces 68 m in the head40 m of the screw 30 m. The spaces 176 between the lobes 174 could besized and contoured to form a slip fit with the lobes 66 m of the screw30 m. Consequently, the portion 182 has a hexalobe axial cross-sectionsimilar to the hexalobe axial cross-section of the recess 50 m.

The inner surface 189 of the opening 190 of a pilot 170 of acorresponding driving tool could be sized and contoured to engage withand/or form a friction fit with the projection 110 m on the screw 30 m.More specifically, the inner surface 189 may have a circular axialcross-section and a frustoconical shape that tapers inwardly in adirection extending from the axial end surface 168 towards the body 160.The axial cross-section and taper of the inner surface 189 could be suchthat the inner surface and projection 110 m (more specifically, thefrustoconical second portion 123 m) could form a provisional engagementand/or friction fit with one another within the recess 190. For example,the inner surface 189 may be sized to deflect the portions of theprojection 110 m inward towards the axis 32 m such that the resistanceof the projection portions to the deflection enhances the provisionalengagement and/or friction fit between the projection and the innersurface (with the second portions 123 m of the projection desirablyurging the portions slightly inward as the opening 190 slides over theprojection). Once within the opening 190, the undercut 124 m can restagainst the walls of the opening 190 and/or engage with a correspondingridge, notch or depression within the opening 190, or could merelyfacilitate deflection of the projection 110 m portions by the innersurface 189 and therefore further help to enhance the mechanical and/orfrictional resistance of the screw to removal from the tool.Furthermore, the deflection of the projection 110 m portions may providean audible “click” or tactile feedback that the provisional engagementhas occurred. The inner surface 189 may be configured to allow the pilot170 to abut the inner end surface 54 m or the pilot may be spaced fromthe inner surface when the provisional engagement and/or friction fit isformed.

If desired, a projection might extend from the axial end surface 191 ofthe opening 190 and be sized and shaped for cooperating with the passage113 m in the screw 30 m to help align the screwdriver 150 and screw 30 malong the axes 32 m, 152. To this end, this projection may have anx-shaped axial cross-section and/or be centered on the axis 152. Inother embodiments, the projection might selectively extend into thepassage 113 m and desirably interfere with deflection or other movementof the projections, and in some embodiments might form a “lockingfeature” which selective locks and/or unlocks the provisional engagementfeature between the screw and the driving tool.

Referring to FIGS. 20A through 20D, another embodiment of a fastenercould incorporate a projection 110 n which comprises a first portion 121n having a cylindrical shape and a second portion 123 n having agenerally hemispherical shape. The first portion 121 n can extend alongthe axis 32 n away from the inner end surface 54 n. The second portion123 n can extend along the axis 32 n from the first portion 121 n awayfrom the inner end surface 54 n. The largest axial cross-section of thesecond portion 123 n may be larger than the axial cross-section of thefirst portion 121 n, thereby forming a lip or undercut section 124 nbetween the first and second portions, with the undercut being rounded,curved, flat, and/or angled (either positive and/or negative and/orreverse angles are contemplated), as desired. The height H₁₄ of theprojection 110 n measured from the inner end surface 54 n to theproximal extent can be less than the depth D1 of the recess 50 m,although the height H₁₅ of the projection 110 m may be equal to orgreater than the depth D1 of the recess 50 n (not shown).

The passage 113 n in the projection 110 n on the screw 30 n can have anx-shaped axial cross-section and extend from the proximal extent towardsthe second end 36 n of the screw 30 n. The passage 113 n can extendsubstantially parallel to the axis 32 n while extending towards thesecond end 36 n of the screw 30 n. The passage 113 n can terminate at aninner end surface 115 n within the projection 110 n, although the innerend surface may alternatively be positioned within the body 80 n or inother locations (not shown). The inner end surface 115 n may thereforebe substantially coplanar with the inner end surface 54 n or spacedaxially from the inner end surface in the proximal or distal directionalong the axis 32 n.

As shown, the passage 113 n extends the entire length of the projection110 n, although the passage may extend through less of the projection,if desired. The passage 113 n extends radially from the axis 32 nthrough the entire projection 110 n and divides the projection into fourdistinct portions. It will be appreciated that the passage 113 n may beconfigured to divide the projection 110 n into more or fewer distinctportions. In any case, the passage 113 n can be centered on the axis 32n and allows the portions of the projection 110 n to radially deflectrelative to the axis and one another.

Although not shown, it will be appreciated that the screwdriver 150 foruse with the screw 30 n of FIGS. 20A through 20D could be configured tocooperate with the screw 30 n in a similar manner to how the screwdriver150 cooperates with the screw 30 of FIGS. 2-4. In particular, with thescrew 30 n of FIGS. 20A through 20D, the lobes 174 of the pilot 170could be sized and contoured to have a slip fit with the spaces 68 n inthe head 40 n of the screw 30 n. The spaces 176 between the lobes 174could be sized and contoured to form a slip fit with the lobes 66 n ofthe screw 30 n. Consequently, the portion 182 could have a hexalobeaxial cross-section similar to the hexalobe axial cross-section of therecess 50 n.

The inner surface 189 of the opening 190 in a pilot 170 of acorresponding driving tool could be sized and contoured to engage withand/or form a friction fit with the projection 110 n on the screw 30 n.More specifically, the inner surface 189 may have a circular axialcross-section and a cylindrical or frustoconical shape (i.e., thattapers inwardly in a direction extending from the axial end surface 168towards the body 160) that desirably includes features that can engagewith the projection. The axial cross-section and smooth walls or taperof the inner surface 189 could be such that the inner surface andprojection 110 n (more specifically, the frustoconical second portion123 n) could engage with and/or form a friction fit with one anotherwithin the recess 190. For example, the inner surface 189 may simply besized to deflect the portions of the projection 110 n inward towards theaxis 32 n such that the resistance of the projection portions to thedeflection enhances the provisional engagement and/or friction fitbetween the projection and the inner surface (with the second portions123 n of the projection desirably urging the portions slightly inward asthe opening 190 slides over the projection). Once within the opening190, the undercut 124 n can rest against the walls of the opening 190and/or engage with a corresponding ridge, notch or depression within theopening 190, or could merely facilitate deflection of the projection 110n portions by the inner surface 189 and therefore further help toenhance the mechanical and/or frictional resistance of the screw toremoval from the tool. The inner surface 189 may be configured to allowthe pilot 170 to abut the inner end surface 54 n or the pilot may bespaced from the inner surface when the provisional engagement and/orfriction fit is formed.

If desired, a projection might extend from the axial end surface 191within the opening 190 and be sized and shaped for cooperating with thepassage 113 n in the screw 30 n to help align the screwdriver 150 andscrew 30 n along the axes 32 n, 152. To this end, this projection mayhave an x-shaped axial cross-section and/or be centered on the axis 152.In other embodiments, the projection might selectively extend into thepassage 113 n and desirably interfere with deflection or other movementof the projections, and in some embodiments might form a “lockingfeature” which selective locks and/or unlocks the provisional engagementfeature between the screw and the driving tool.

One particular utilitarian feature of the embodiments of FIGS. 14Athrough 15D and 17A through 20D is the ability of the various screwembodiments to accommodate a wide variety of driving toolconfigurations, if desired. For example, the placement of notches 117 nin the walls of the head 42 n could accommodate the “tangs” or drivingsurfaces of a Phillip's Head screwdriver and/or the blades of a flatheadscrewdriver (which can also be accommodated by the passage 113 n, whilethe remainder of the recess could accommodate a hexalobular driver, aspreviously described. Alternatively, the projections of the variousembodiments might also incorporate features capable of accommodatingdifferent types of socket wrenches, if desired. If desired, the wallsfeatures of the recess could be altered to accommodate both ahexalobular driver and a hexagonal driver. By combining various drivingfeatures such as those described herein, the present fasteners couldaccommodate a variety of driving tools, and potentially simplify thetool requirements for a user of the system.

In other alternative embodiments, the various provisional retentionfeatures described herein could be incorporated into other types offasteners, including fasteners having driving surfaces formed on anoutside of the fastener head (i.e., a hex-head bolt driven by a socketdriver). In various embodiments, the fastener head could incorporate ahead with a recess formed therein, and a projection of other feature atleast partially disposed within the recess that provisionally engageswith a centrally-formed opening in the driving tool (in a manner similarto the embodiments previously described), and the inner walls of thesocket driver engaging the driving surfaces on the outside of the bolthead.

FIGS. 21A through 22D depict various exemplary configurations for adriving tool or screwdriver having a driving tip with a pilot openingformed therein. These figures depict a variety of alternativeconfigurations that incorporate various provisional engagement featuresfor the fastening tool. In these figures, similar components for manyfeatures to those found in FIGS. 5-6B have been given the same referencenumeral with the added suffix “a”, “b”, “c”, “d”, and “e”, respectively.Although not shown or specifically described in many embodiments, itshould be understood that virtually any combination of the variousfastening tool features described herein could be combined, and the toolwould desirably be appropriately contoured, shaped and/or sized to theshapes of the recess and/or projection, which could include identicalconfigurations or configurations capable of engaging with correspondingfeatures in each of the alternative configurations of FIGS. 8A-20D. Invarious described embodiments, a corresponding pilot inner surface andscrew head projection could be designed to provide appropriateprovisional engagement structures and their related relationships witheach other, such as a friction fit, to provide similar or the sameadvantages as the screw 30 and screwdriver 150 of FIGS. 1-6B.

FIG. 22A depicts a cross-sectional view of one exemplary embodiment of adriving tool pilot incorporating an opening 190 b for accommodating aprojection of a fastener, such as those described in the variousembodiments herein. In this embodiment, the opening 190 b comprises agenerally frustoconical shape 189 b, which may be formed in the shape ofa Morse taper or other known configurations. Desirably, the walls of theopening will engage with and retain a corresponding projection of afastener, which in various embodiments could incorporate correspondingtapered walls, cylindrical walls and/or deflectable projections. Alsodepicted are tapered or rounded portions 171 b, which desirablyfacilitate placement of the tool onto the projections and/or into therecess of the fastener. A space 172 b can be included to simplifymachining of the opening 190 b by known techniques.

FIG. 22B depicts a cross-sectional view of another exemplary embodimentof a driving tool pilot incorporating an opening 190 c for accommodatinga projection of a fastener, such as those described in the variousembodiments herein. In this embodiment, the opening 190 c comprises agenerally frustoconically shaped opening 189 c, which may be formed inthe shape of a Morse taper or other known configurations. The openingfurther includes a recessed or notched portion 173 c, which desirablyengages with a corresponding projection of a fastener, which in variousembodiments could incorporate corresponding tapered walls, cylindricalwalls and/or deflectable projections with overhanging lips, etc. Alsodepicted are tapered or rounded portions 171 c, which desirablyfacilitate placement of the tool onto the projections and/or into therecess of the fastener. A space 172 c can be included to simplifymachining of the opening 190 c by known techniques.

FIG. 22C depicts a cross-sectional view of another alternativeembodiment of a driving tool pilot incorporating an opening 190 c foraccommodating a projection of a fastener, such as those described in thevarious embodiments herein. In this embodiment, the opening 190 ccomprises a generally cylindrical shape 189 d with a terminal space 172c. Desirably, the walls of the opening will engage with and retain acorresponding projection of a fastener, which in various embodimentscould incorporate corresponding tapered walls, cylindrical walls and/ordeflectable projections. Also depicted are tapered or rounded portions171 d, which desirably facilitate placement of the tool onto theprojections and/or into the recess of the fastener.

FIG. 22D depicts a cross-sectional view of another exemplary embodimentof a driving tool pilot incorporating an opening 190 e for accommodatinga projection of a fastener, such as those described in the variousembodiments herein. In this embodiment, the opening 190 e comprises agenerally frustoconically shaped opening 189 e. The opening furtherincludes a recessed or notched portion 173 e, which desirably engageswith a corresponding projection of a fastener, which in variousembodiments could incorporate corresponding tapered walls, cylindricalwalls and/or deflectable projections with overhanging lips, etc. Alsodepicted are tapered or rounded portions 171 e, which desirablyfacilitate placement of the tool onto the projections and/or into therecess of the fastener. A space 172 e can be included to simplifymachining of the opening 190 e by known techniques.

Another particularly useful feature of the various embodiments disclosedherein is the ability of the system to be utilized with non-ferrousand/or non-magnetic materials (i.e., fasteners and/or driving tools).Unlike magnetic retention bits, which require ferrous or magneticscrews, the features of the present invention can be utilized withvirtually any materials (i.e., stainless steel, titanium, plastics,ceramics, etc.) and can be used in virtually any environment, even wherethe use of ferrous materials and/or magnetic devices may be undesirableand/or prohibited (i.e., in high-energy electrical environments and/ornear high-strength magnets such as contained in Magnetic ResonanceImaging machines).

In various embodiments, the dimensions, shapes and tolerancing of thevarious fasteners and driving tools described herein can beparticularized to a specific application. For example, if a greateramount of retention force is desired for the provisional engagementfeature, the taper of the opening can be altered to increase the holdingstrength. Conversely, if less holding force is desired, the taper of theopening can reduced and/or increased accordingly. Similarly, the depthsof the opening and/or length of the projection can be altered, withgreater dimensions typically increasing the holding strength. Similarly,the relative shapes and/or sizes of the projection(s) and/or opening inthe pilot could be altered to provide greater or lesser holding forces.In other embodiments, the size, shape, surface features, thicknessand/or stiffness of the projections could be altered, with commensuratealterations to the provisional holding strength of the fastener to thetool. In other embodiments, the angle of the undercut on a projectionand/or inner wall of a notch in the tool opening can be altered (i.e.,90°, 60°, 45°, etc.) to desirably alter the holding force.

The embodiments herein describe engagement features for the variousfasteners and tools that are relatively inexpensive and easily formed,and are particularly robust in their applications. For example, theopening in the pilot of the driving tool can be formed via a simpledrilling and/or machining operation, and the simplified design is highlyresistant to fatigue and/or failure during the repeated applicationand/or removal of numerous fasteners accomplished with a single drivingtool. Moreover, the projection(s) incorporated into the recess of eachfastener are unlikely to fracture and/or failure (i.e., due to materialfatigue) during the limited number of times that the fastener isexpected to be attached and/or removed from the work piece, and thus theopportunity for failure of these components is also greatly reduced.Moreover, the ability to incorporate the various features into manyexisting fastener and driving tool designs greatly enhances thecost-effectiveness and utility of the various features described herein.

The screws and screwdrivers of the present invention are advantageous inthat the provisional engagement and/or friction fit between theprojection and pilot reliably retains the screw on the screwdriverwithout manual assistance. Furthermore, the limited number of sides onthe projection that cooperate with the recess in the screwdriver help toensure a reliable, repeatable connection therebetween. Morespecifically, by limiting the number of cooperating surfaces between thescrew projection and screwdriver recess forming the provisionalengagement and/or friction fit, machining tolerances can be morereliably held to form a precise provisional engagement and/or frictionfit. Conversely, the slip fit connection between the pilot and innersurface of the recess can be made with more forgiving tolerances, whichis beneficial given the increased number of cooperating surfaces betweenthe pilot and inner surface of the screw, and in various embodiments thedisclosed design features can provide an adequate provisional engagementforce even where sloppy or poor manufacturing and/or tolerancing ofengagement features exists. Moreover, embodiments that provide aprojection on the screw that does not extend out of the recessadvantageously can reduce the risk of projection breakage and minimizeinteraction between the screw and the surrounding structure.

What have been described above are examples of the present invention. Itis, of course, not possible to describe every conceivable combination ofcomponents or methodologies for purposes of describing the presentinvention, but one of ordinary skill in the art will recognize that manyfurther combinations and permutations of the present invention arepossible. Accordingly, the present invention is intended to embrace allsuch alterations, modifications and variations that fall within thespirit and scope of the appended claims. Although the foregoinginvention has been described in some detail by way of illustration andexample for purposes of clarity of understanding, it will be readilyapparent to those of ordinary skill in the art in light of the teachingsof this invention that certain changes and modifications may be madethereto without departing from the spirit or scope of the disclosureherein. For example, it will be understood that a screw in accordancewith the present invention may include any combination of axiallyextending inner surface 52-52 n and projections 110-100 n shown and/ordescribed herein.

The invention may be embodied in other specific forms without departingfrom the spirit or essential characteristics thereof. The foregoingembodiments are therefore to be considered in all respects illustrativerather than limiting on the invention described herein. Scope of theinvention is thus intended to include all changes that come within themeaning and range of equivalency of the descriptions provided herein.

The various headings and titles used herein are for the convenience ofthe reader, and should not be construed to limit or constrain any of thefeatures or disclosures thereunder to a specific embodiment orembodiments. It should be understood that various exemplary embodimentscould incorporate numerous combinations of the various advantages and/orfeatures described, all manner of combinations of which are contemplatedand expressly incorporated hereunder.

The use of the terms “a” and “an” and “the” and similar referents in thecontext of describing the invention are to be construed to cover boththe singular and the plural, unless otherwise indicated herein orclearly contradicted by context. The terms “having,” “including,” and“containing” are to be construed as open-ended terms (i.e., meaning“including, but not limited to,”) unless otherwise noted. Recitation ofranges of values herein are merely intended to serve as a shorthandmethod of referring individually to each separate value falling withinthe range, unless otherwise indicated herein, and each separate value isincorporated into the specification as if it were individually recitedherein. All methods described herein can be performed in any suitableorder unless otherwise indicated herein or otherwise clearlycontradicted by context. The use of any and all examples, or exemplarylanguage (e.g., i.e., “such as”) provided herein, is intended merely tobetter illuminate the invention and does not pose a limitation on thescope of the invention unless otherwise claimed. No language in thespecification should be construed as indicating any non-claimed elementas essential to the practice of the invention.

What is claimed is:
 1. A screw extending along an axis and having a proximal end and a distal end, the screw comprising: a head located at the proximal end, the head having an axial end surface and an axially extending first inner surface defining a recess, the recess extending from the axial end surface towards the distal end of the screw and terminating at a second inner surface; a projection extending from the second inner surface towards the axial end surface and termination at a proximal extent, the projection having at least one mating feature for provisionally engaging with a driving tool; and a shaft extending from the head, the shaft having an externally facing thread for securing the screw into a structure.
 2. The screw of claim 1, wherein the projection has a polygonal axial cross-section.
 3. The screw of claim 1, wherein the projection extends from the second inner surface towards the axial end surface and terminates at a proximal extent, the mating feature comprising an outer surface that frictionally engages with the driving tool.
 4. The screw of claim 3, wherein a height of the projection from the second inner surface to the proximal extent is less than a depth of the recess from the axial end surface to the second inner surface.
 5. The screw of claim 3, wherein the first inner surface defines a plurality of lobes that encircle the projection.
 6. The screw of claim 3, wherein the first inner surface defines a polygonal recess.
 7. The screw of claim 6, wherein the polygonal axial cross-section has concave sides.
 8. The screw of claim 3, wherein the projection has a frustoconical shape.
 9. The screw of claim 8, wherein the projection has a hemispherical portion defining the proximal extent.
 10. The screw of claim 3, wherein the proximal extent comprises an axial end surface of the projection, arcuate sides extending from the axial end surface of the projection to the second inner surface.
 11. The screw of claim 3, wherein the projection divides the recess into a plurality of discrete portions.
 12. A screw and screwdriver combination comprising: a screw extending along an axis and having a proximal end and a distal end, a head located at the proximal end having an axial end surface and an axially extending first inner surface defining a recess, the recess extending from the axial end surface towards the distal end of the screw and terminating at a second inner surface, the screw further including a shaft extending from the head and having a thread for securing the screw in a structure; and a screwdriver extending along an axis and having a proximal end and a distal end, a handle being located at the proximal end of the screwdriver and a shaft extending distally from the handle, a pilot located at the distal end of the screwdriver cooperating with the first inner surface of the screw.
 13. The screw and screwdriver combination of claim 12, wherein the pilot forms a slip fit with the first inner surface of the screw.
 14. The screw and screwdriver of claim 12, wherein the recess of the screw has a polygonal axial cross-section, the pilot of the screwdriver having a polygonal axial cross-section that forms a slip fit with the first inner surface of the screw.
 15. The screw and screwdriver of claim 12, wherein a projection extends from the second inner surface towards the axial end surface and terminates at a proximal extent, the pilot having an inner surface forming a friction fit with the projection of the screw.
 16. The screw and screwdriver of claim 15, wherein the first inner surface of the screw defines a plurality of lobes that encircle the projection, the pilot of the screwdriver defining a plurality of lobes that form a slip fit with the lobes of the screw.
 17. The screw and screwdriver of claim 15, wherein the projection on the screw and the inner surface of the screwdriver each has a frustoconical shape that form a friction fit with one another.
 18. The screw and screwdriver of claim 15, wherein the projection on the screw and the inner surface of the screwdriver each has a circular axial cross-section.
 19. The screw and screwdriver of claim 15, wherein the projection on the screw and the recess in the screwdriver each has a polygonal axial cross-section.
 20. The screw and screwdriver of claim 19, wherein the polygonal axial cross-section of the projection has concave sides and the polygonal axial cross-section of the recess of the screwdriver has convex sides. 